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3618 ENGINE
Maintenance Intervals
Excerpted from Operation & Maintenance Manual (SEBU7150-05-01)
© 2007 Caterpillar
All Rights Reserved
SEBU7150-05
55
Maintenance Section
Maintenance Interval Schedule
i02696000
Maintenance Interval Schedule
SMCS Code: 1000; 4450; 7500
Ensure that all safety information, warnings and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
Use mileage, fuel consumption, service hours, or
calendar time, WHICHEVER OCCURS FIRST,
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
62
69
69
73
79
79
80
81
83
84
Daily
Air Starting Motor Lubricator Oil Level - Check ....
Air Tank Moisture and Sediment - Drain ...............
Annunciator Panel - Inspect ..................................
Cooling System Coolant Level - Check ................
Driven Equipment - Inspect/Replace/Lubricate ...
Engine Oil Level - Check ......................................
Fuel System Primary Filter/Water Separator Drain ...................................................................
Fuel Tank Water and Sediment - Drain .................
Oil Mist Detector - Maintain ..................................
Trend Data - Record .............................................
Walk-Around Inspection ........................................
66
66
66
72
84
Every 500 Service Hours or 3 Months
The user is responsible for the performance of
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Centrifugal Oil Filter - Clean .................................
Engine Air Cleaner Element - Replace .................
Engine Crankcase Breather - Clean .....................
Engine Oil and Filter - Change .............................
Fuel Analysis - Obtain ...........................................
Fuel System - Prime .............................................
Fuel System Primary Filter (Water Separator)
Element - Replace ..............................................
Fuel System Secondary Filter - Replace ..............
Metal Particle Detector - Inspect ...........................
Oil Mist Detector - Maintain ..................................
Cooling System Coolant Sample (Level 1) Obtain .................................................................
Cooling System Coolant Sample (Level 2) Obtain .................................................................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Oil Sample - Obtain ..................................
Oil Mist Detector - Maintain ..................................
59
59
60
65
68
72
80
83
84
91
95
Every 250 Service Hours or Monthly
Air Starting Motor Lines Screen - Clean ............... 58
Barring Device - Lubricate ....................................
Engine Mounts - Inspect .......................................
Governor Actuator Linkage - Check .....................
Oil Mist Detector - Maintain ..................................
60
71
83
84
Initial 1000 Service Hours or 6 Months
Engine Timing, Synchronization, and Valve Lash Inspect/Adjust ..................................................... 77
Engine Valve Rotators - Inspect ........................... 78
Every 1000 Service Hours or 6 Months
Engine Mounts - Check ........................................ 69
Every 2000 Service Hours or 1 Year
Centrifugal Oil Filter - Inspect ............................... 62
Engine Protective Devices - Check ...................... 76
Engine Timing, Synchronization, and Valve Lash Inspect/Adjust ..................................................... 77
Engine Valve Rotators - Inspect ........................... 78
Oil Mist Detector - Maintain .................................. 84
Every 4000 Service Hours or 1 Year
Aftercooler Core - Clean/Test ...............................
Air Starting Motor Lubricator Bowl - Clean ...........
Crankshaft Vibration Damper - Inspect .................
Driven Equipment - Check ....................................
Exhaust Shields - Inspect .....................................
Starting Motor - Inspect ........................................
Turbocharger - Inspect ..........................................
Water Pump - Inspect ...........................................
57
58
67
68
78
91
94
96
Every 8000 Service Hours or 2 Years
Cooling System Coolant - Change ....................... 62
Between 12 605 000 and 14 763 000 L
(3 330 000 and 3 900 000 US gal) of Fuel or
between 10 000 and 12 000 Service Hours
Camshaft Roller Followers - Inspect .....................
Engine Oil Temperature Regulator - Replace .......
Overhaul (Top End) ...............................................
Overhaul Considerations ......................................
Water Temperature Regulator - Replace ..............
61
73
87
88
96
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Maintenance Section
Maintenance Interval Schedule
Between 25 211 000 and 29 526 000 L
(6 660 000 and 7 800 000 US gal) of Fuel or
Between 20 000 and 24 000 Service Hours
Overhaul (Major) ................................................... 85
Overhaul Considerations ...................................... 88
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SEBU7150-05
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Maintenance Section
Aftercooler Core - Clean/Test
i01916525
Table 21
Aftercooler Core - Clean/Test
Liquid Cleaners(1)
Part
Number
Description
1U-5490
Hydrosolv 4165
19 L (5 US gallon)
174-6854
Caterpillar Cabinet
and Tank Liquid
Cleaner
19 L (5 US gallon)
174-6855
Caterpillar Cabinet
and Tank Liquid
Cleaner
208 L (55 US gallon)
SMCS Code: 1064-070; 1064-081; 1064
Before cleaning the aftercooler core, determine if the
aftercooler requires cleaning. Use the 152-2067
Differential Pressure Gauge to measure the
differential pressure of the air side of the aftercooler. If
the differential pressure of the air side is greater than
10 kPa (40 inches of H2O), clean the aftercooler core.
Cleaning the Aftercooler
See the Service Manual, “Disassembly and
Assembly” module for instructions on removal,
disassembly, assembly, and installation.
1. Remove the core.
2. Turn the core upside-down in order to remove
debris.
NOTICE
Do not use a high pressure spray for cleaning the fins
of the core. A high pressure spray can damage the
surface of the fins and reduce the flow of air through
the core.
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.
3. Back flush the core with cleaner. Table 21 lists
liquid cleaners that are available from your
Caterpillar dealer.
Use a two to five percent concentration of the
cleaner at temperatures up to 93 °C (200 °F).
Refer to Application Guide, NEHS0526 or consult
your Caterpillar dealer for more information.
(1)
Size
Use a two to five percent concentration of the cleaner
at temperatures up to 93°C (200°F). Refer to Application
Guide, NEHS0526 or consult your Caterpillar dealer for more
information.
4. Steam clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
7. Inspect the core in order to ensure cleanliness.
Pressure test the core to a pressure of 1.5 times
the working pressure of the cooling circuit for
one hour. Many shops that service radiators are
equipped to perform pressure tests. If necessary,
repair the core.
8. Install the core.
For more information on cleaning the core, consult
your Caterpillar dealer.
58
Maintenance Section
Air Starting Motor Lines Screen - Clean
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i01762654
Air Starting Motor Lines
Screen - Clean
Personal injury can result from removing hoses or
fittings in a pressure system.
SMCS Code: 1451-070-LI
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
1. Ensure that the air supply to the lubricator is OFF.
Illustration 44
g00789123
(1) Plug
(2) Screen
If the engine is equipped with an air starting motor,
use the following procedure:
g01333332
1. Ensure that the air supply to the air lines is OFF.
Illustration 45
2. Remove plug (1).
(1) Filler plug
(2) Bowl
(3) Drain valve
3. Carefully remove screen (2). Clean the screen
with nonflammable solvent. Inspect the screen for
damage. If the screen is damaged, replace the
damaged screen with a new screen.
2. Slowly loosen filler plug (1) in order to release the
pressure from the lubricator.
4. Install clean, dry screen (2). Clean plug (1). Install
the plug.
i02654935
Air Starting Motor Lubricator
Bowl - Clean
SMCS Code: 1451-070
If the engine is equipped with an air starting motor,
use the following procedure:
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
3. Place a suitable container under bowl (2) and
open drain valve (3) in order to drain the oil from
the bowl.
4. Remove bowl (2). Clean the bowl with warm water.
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59
Maintenance Section
Air Starting Motor Lubricator Oil Level - Check
5. Dry the bowl. Inspect the bowl for cracks. If the
bowl is cracked, replace the damaged bowl with
a new bowl. Inspect the gasket. If the gasket is
damaged, replace the gasket.
6. Install the bowl.
3. Remove filler plug (4). Pour oil into the lubricator
bowl. Use nondetergent SAE 10W oil for
temperatures that are greater than 0 °C (32 °F).
Use air tool oil for temperatures that are below
0 °C (32 °F).
4. Install filler plug (4).
7. Make sure that drain valve (3) is closed.
8. For instructions on filling the lubricator, see this
Operation and Maintenance Manual, “Air Starting
Motor Lubricator Oil Level - Check” topic.
i02654969
Air Starting Motor Lubricator
Oil Level - Check
SMCS Code: 1451-535
NOTICE
Never allow the lubricator bowl to become empty. The
air starting motor will be damaged by a lack of lubrication. Ensure that sufficient oil is in the lubricator bowl.
Adjust the Lubricator
Note: Adjust the lubricator with a constant rate of air
flow. After the adjustment, the lubricator will release
oil in proportion to variations of the air flow.
1. Ensure that the fuel supply to the engine is OFF.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
2. Operate the air starting motor. Observe the drops
of oil that are released in dome (1).
Note: Some lubricators have an adjustment screw
rather than a knob.
3. If necessary, adjust the lubricator in order
to release from one to three drops of oil per
second. To increase the rate, turn knob (2)
counterclockwise. To decrease the rate, turn the
knob clockwise.
i00351324
Air Tank Moisture and
Sediment - Drain
Illustration 46
g01333366
1. Observe the oil level in sight gauge (3). If the oil
level is less than 1/2, add oil to the lubricator bowl.
SMCS Code: 1466-543-M&S
Moisture and sediment in the air starting system can
cause the following conditions:
• Freezing
Personal injury can result from removing hoses or
fittings in a pressure system.
• Corrosion of internal parts
• Malfunction of the air starting system
Failure to relieve pressure can cause personal injury.
Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
2. Ensure that the air supply to the lubricator is OFF.
Slowly loosen filler plug (4) in order to release
pressure from the lubricator bowl.
When opening the drain valve, wear protective
gloves, a protective face shield, protective clothing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury.
60
Maintenance Section
Annunciator Panel - Inspect
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1. Open the drain valve that is on the bottom of the
air tank. Allow the moisture and sediment to drain.
2. Close the drain valve.
i01903909
Annunciator Panel - Inspect
SMCS Code: 1926
Inspect the annunciator panel for good condition.
Perform a lamp test. All of the warning lamps should
illuminate. If a warning lamp does not illuminate,
replace the bulb immediately. If the alarm does
not sound, investigate the problem and correct the
problem.
Fuel Filter Differential Pressure
Replace the fuel filter elements when either of the
following situations occur:
• The engine is operating at rated speed and at
operating temperature and the fuel filter differential
pressure reaches 69 kPa (10 psi).
• The fuel filter elements have been used for 1000
hours of operation.
Air Restriction
When the air restriction reaches 3.7 kPa
(15 inch of H2O) then replace the soot filter. If the
air restriction exceeds this limit, excessive fuel
consumption and exhaust temperatures will result.
Check the Gauges
Check the condition of all of the gauges. If a gauge
is broken, repair the gauge or replace the gauge
immediately.
Record the Data and Review the Data
Check the oil pressure and the fuel pressure on an
hourly basis during normal operation. Record the
data in a log. Compare the new data to the data
that was previously recorded. Comparing the new
data to the recorded data will establish the normal
gauge readings for the engine. A gauge reading that
is abnormal may indicate a problem with operation or
a problem with the gauge.
Oil Pressure
Normal oil pressure at low idle rpm and at operating
temperature is 172 kPa (25 psi). Normal oil pressure
at rated rpm and at operating temperature is 448 kPa
(65 psi).
i01904523
Barring Device - Lubricate
SMCS Code: 1235-086
NOTICE
Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
tooth failure.
Guards must be in place prior to operating barring
device motor.
Remove all hand tools prior to operating barring
device motor.
Oil Filter Differential Pressure
Replace the oil filter elements when one or more of
the following situations occur:
• The engine is operating at rated speed and at
operating temperature and the oil filter differential
pressure reaches 103 kPa (15 psi).
• The engine oil is changed.
Fuel Pressure
The typical fuel pressure range is from 450 kPa
(65 psi) at low idle to 700 kPa (102 psi) at high idle.
Illustration 47
g00334420
Rear view of a barring device with an electric motor
Note: Prelube of the engine is recommended before
the crankshaft is rotated for normal maintenance.
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Maintenance Section
Camshaft Roller Followers - Inspect
The barring device provides a means for slowly
turning the flywheel in order to service the engine.
The barring device can also be used to prevent
rotation of the crankshaft. When the barring device is
in the engaged position, the engine starting system
is disabled.
Lubricating the Reducer
When the barring device is not used, the barring
device must be fully disengaged from the flywheel
and secured in the disengaged position.
NOTICE
Do not operate the engine starting motor until the barring group pinion gear is fully disengaged from the flywheel ring gear. Serious damage to the engine could
result.
Lubricating the Pinion
Illustration 49
g00991445
1. Ensure that the barring device is locked in the
disengaged position.
2. Remove level plugs (2) and check the lubricant
level.
3. If necessary, remove cap (1) and add Caterpillar
4C-6767 Synthetic Oil until the oil is visible at the
level plugs.
4. Reinstall the level plugs and reinstall the cap.
i01904185
Illustration 48
g00991436
Section view of a barring device without an electric motor
(1) Grease fitting
(2) Vent
1. Ensure that the barring device is locked in the
disengaged position.
2. Lubricate grease fitting (1) with MPGM until the
grease is visible at vent (2).
Camshaft Roller Followers Inspect
SMCS Code: 1209-040
For instructions on disassembly and assembly of
the valve lifter group, see the Service Manual,
“Disassembly and Assembly” module.
Inspect the following components for wear at each
metal to metal contact point:
• Rollers for the valve lifters
• Camshaft
Inspect each roller for wear, excessive movement,
and end play.
If excessive wear or other signs of deterioration are
found, replace the damaged components.
62
Maintenance Section
Centrifugal Oil Filter - Clean
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i01317136
i01317156
Centrifugal Oil Filter - Clean
Centrifugal Oil Filter - Inspect
SMCS Code: 1328-070
SMCS Code: 1328-040
Hot oil and components can cause personal injury.
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact
skin.
Do not allow hot oil or components to contact
skin.
Intervals for cleaning the centrifugal oil filters depend
on the buildup of sludge in the centrifugal oil filters.
After disassembling the centrifugal oil filter, measure
the buildup of sludge in the rotor cover.
Note: To prevent oil from spraying, the engine should
be shut down prior to removal of the centrifugal oil
filter. The shutoff valve for the filter must also be in
the closed position.
If the buildup of sludge is more than 12 mm (.47 inch)
thick, the centrifugal oil filters must be cleaned more
often.
1. Disassemble the centrifugal oil filter according
to the instructions in the Service Manual,
“Disassembly and Assembly”.
If the buildup of sludge is not more than 12 mm
(.47 inch) thick, clean the centrifugal oil filters after
every 100 operating hours.
2. Thoroughly clean all of the parts of the filter.
Carefully inspect all of the parts.
If the buildup of sludge is less than 12 mm (.47 inch)
thick, the interval for cleaning the centrifugal oil filters
can be increased. Increase the interval in 50 hour
increments until a suitable interval is determined.
Note: To prevent oil from spraying, shut down the
engine prior to removal of the centrifugal oil filter. The
shutoff valve for the centrifugal oil filter must also be
in the closed position.
1. Disassemble the centrifugal oil filter according
to the instructions in the Service Manual,
“Disassembly and Assembly”.
2. Thoroughly clean all of the parts of the filter.
Carefully inspect all of the parts.
NOTICE
Ensure that all of the rotor components are thoroughly
clean before assembling the rotor. Failure to do so can
cause an out of balance condition that can cause rapid
wear to the bearings and the spindle.
Note: Install a new paper liner when the filter is
assembled.
3. Assemble the filter according to the instructions in
the Service Manual, “Disassembly and Assembly”.
3. Measure the clearance between the bearing and
the base and measure the clearance between the
bearing and the spindle. Follow the instructions
that are in the Service Manual. Replace any part
that does not meet the specifications that are in
the Service Manual.
NOTICE
Ensure that all of the rotor components are thoroughly
clean before assembling the rotor. Failure to do so can
cause an out of balance condition that can cause rapid
wear to the bearings and the spindle.
Note: Install a new paper liner when the filter is
assembled.
4. Assemble the centrifugal oil filter according to the
instructions in the Service Manual, “Disassembly
and Assembly”.
i02554244
Cooling System Coolant Change
SMCS Code: 1350-044
Clean the cooling system before the recommended
maintenance interval if the following conditions exist:
• The engine overheats frequently.
• Foaming is observed.
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63
Maintenance Section
Cooling System Coolant - Change
• Oil or fuel has entered the cooling system and the
coolant is contaminated.
NOTICE
Use of commercially available cooling system cleaners may cause damage to cooling system components. Use only cooling system cleaners that are approved for Caterpillar engines.
Drain the Cooling System
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
cooling system is drained.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
Illustration 51
g00702438
(4) Location of the vent valves for the aftercooler and oil cooler
system
(5) Location of the vent valves for the jacket water system
(AA) Vent valve
Note: Vent valves (4) and (5) must be open during
engine operation.
3. Ensure that vent valves (4) and (5) are open
during this procedure. Open the cooling system
drain valves or drain plugs (1), (2), and (3). Allow
the coolant to drain.
Illustration 50
g00702833
(1) Drain for the jacket water pump
(2) Drain for the water pump of the aftercooler and oil cooler system
(3) Drain for the elbow for the jacket water on the left side of the
engine
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Clean the Cooling System
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
and install the cooling system drain plugs.
64
Maintenance Section
Cooling System Coolant - Change
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start the engine. Operate the engine for a
minimum of 30 minutes with a coolant temperature
of at least 82°C (180°F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
cooling system with clean water until the water
that drains is clean. Close the cooling system
drain valves (if equipped). Clean the cooling
system drain plugs and install the cooling system
drain plugs.
Cleaning a Cooling System that
has Heavy Deposits or Plugging
Note: For the following procedure to be effective,
there must be an active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris.
SEBU7150-05
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(1 to 2 US gal) of the cooling system capacity.
Install the cooling system filler cap.
4. Start the engine. Operate the engine for a
minimum of 90 minutes with a coolant temperature
of at least 82°C (180°F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear water. Continue to flush the system until all signs of the
cleaning agent are gone.
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valves (if equipped) or remove the cooling system
drain plugs. Allow the water to drain. Flush the
cooling system with clean water until the water
that drains is clean. Close the cooling system
drain valves (if equipped). Clean the cooling
system drain plugs and install the cooling system
drain plugs.
Fill the Cooling System
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system with water and SCA. For
information about the proper mixture to use, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations”. For the
capacity of the cooling system, see this Operation
and Maintenance Manual, “Refill Capacities and
Recommendations”. Do not install the cooling
system filler cap.
2. Close the cooling system drain valves (if
equipped). Clean the cooling system drain plugs
and install the cooling system drain plugs.
2. Start the engine. Operate the engine in order to
purge the air from the cavities of the engine block.
Allow the coolant to warm and allow the coolant
level to stabilize. Stop the engine.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Check the coolant level. Maintain the coolant to
the proper level on the sight gauge (if equipped).
If a sight gauge is not equipped, maintain the
coolant within 13 mm (.5 inch) below the bottom of
the filler pipe.
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65
Maintenance Section
Cooling System Coolant Level - Check
4. Clean the cooling system filler cap. Inspect
the gaskets of the cooling system filler cap. If
the gaskets of the cooling system filler cap are
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
gaskets of the cooling system filler cap are not
damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap.
The correct pressure is stamped on the face of
the cooling system filler cap. If the cooling system
filler cap does not retain the correct pressure,
install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i02158408
Cooling System Coolant Level
- Check
SMCS Code: 1350-535-FLV
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
Check the coolant level when the engine is stopped
and cool. Check the coolant level only after the
engine has been stopped and the cooling system
filler cap is cool enough to touch with your bare hand.
Remove the cooling system filler cap slowly in order
to relieve any pressure. Maintain the coolant within
13 mm (0.5 inch) below the bottom of the filler pipe.
Add Coolant
Climbing equipment may be required to access
this service point. Refer to the Operation and
Maintenance Manual, “Mounting and Dismounting” topic for safety information.
Engines That Are Equipped With a
Sight Gauge
Illustration 52
Engines That Are Not Equipped
With a Sight Gauge
g00750429
(1) Filler cap
(2) Sight gauge
If the engine is equipped with a sight gauge, observe
the position of the coolant in the sight gauge. At
normal operating temperature, the proper coolant
level is in the upper half of the sight gauge. If the
coolant level is low, add the proper coolant mixture.
Note: For the proper coolant mixture to use, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Section).
1. Stop the engine. Allow the engine to cool.
2. Remove the cooling system filler cap slowly in
order to relieve any pressure. Pour the proper
coolant mixture into the filler pipe.
Illustration 53
g00103639
Gaskets
3. Clean the cooling system filler cap. Inspect the
gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
4. Start the engine. Inspect the cooling system for
leaks.
66
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
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i02693129
i02469122
Cooling System Coolant
Sample (Level 1) - Obtain
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA
can be checked by using a 298-5311 Coolant Nitrite
Test Kit.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
Use the following guidelines for proper sampling of
the coolant:
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
Submit the sample for Level 2 analysis.
For additional information about coolant analysis,
see the Special Publication, SEBU7003, “3600
Series and C280 Series Diesel Engine Fluids
Recommendations” or consult your Caterpillar dealer.
i02322137
Cooling System Supplemental
Coolant Additive (SCA) Test/Add
SMCS Code: 1352-045; 1395-081
Note: Level 1 results may indicate a need for
Level 2 Analysis.
For additional information about coolant analysis,
see this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” or consult your
Caterpillar dealer.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
coolant additive.
Note: Test the concentration of the SCA or obtain an
S·O·S coolant analysis (Level I).
SEBU7150-05
67
Maintenance Section
Crankshaft Vibration Damper - Inspect
Test the Concentration of the SCA
i02623987
Water and SCA
Crankshaft Vibration Damper
- Inspect
NOTICE
Do not exceed the recommended eight percent supplemental coolant additive concentration.
SMCS Code: 1205-040
Test the concentration of the SCA with the 210-2606
Coolant Conditioner Test Kit. Follow the instructions
that are in this Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic.
Add the SCA, If Necessary
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Remove the cooling system filler cap slowly.
Note: Always dispose of fluids according to local
regulations.
2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.
NOTICE
Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine’s
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentration could also result in blockage of the heat exchanger, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supplemental coolant additive concentration.
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has
a weight that is located inside a fluid filled case.
Damage to the crankshaft vibration damper or failure
of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
engine components. A deteriorating damper can
cause excessive gear train noise at variable points
in the speed range.
A damper that is hot may be the result of excessive
friction. This could be due to misalignment. Use an
infrared thermometer to monitor the temperature
of the damper during operation. If the temperature
reaches 93 °C (200 °F), consult your Caterpillar
dealer.
Inspect the damper for evidence of dents, cracks,
and leaks of the fluid.
If a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has the
following characteristics: transparent, viscous, and
smooth.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace all of the seals.
Inspect the damper and repair or replace the damper
for any of the following reasons.
• The damper is dented, cracked, or leaking.
• The paint on the damper is discolored from heat.
• The engine has had a failure because of a broken
crankshaft.
• The crankshaft bearings are showing excessive
wear.
• There is a large amount of gear train wear that is
not caused by a lack of oil.
3. Add the proper amount of SCA. See this Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” topic.
4. Clean the cooling system filler cap. Install the
cooling system filler cap.
68
Maintenance Section
Driven Equipment - Check
SEBU7150-05
Dampers With Sampling Ports
i01904417
Driven Equipment - Check
SMCS Code: 3279-535
To minimize bearing problems and vibration of the
engine crankshaft and the driven equipment, the
alignment between the engine and driven equipment
must be maintained properly.
Check the alignment according to the commissioning
data and refer to the instructions that are provided by
the following manufacturers:
• Caterpillar
• OEM of the coupling
• OEM of the driven equipment
• OEM of the vessel
Illustration 54
g00819045
Some dampers have ports for fluid samples. If the
damper has no external damage, collect a 2 to 5
mL sample of the damper fluid. The fluid should be
analyzed in order to check for a loss of viscosity. Use
the results of the analysis to determine if the damper
should be rebuilt or replaced. Kits for fluid samples
are available from the address that follows. Return
the kits to the same address for analysis.
Hasse & Wrede GmbH
Mohriner Allee 30-42
D-12347 Berlin
Germany
Phone: 49 30 / 70 181 195
Fax: 49 30 / 70 09 08-11
Note: Caterpillar recommends the use of laser
alignment tools in order to check the alignment of the
driven equipment. Refer to the documentation above
for specifications and alignment procedures.
i00935098
Driven Equipment Inspect/Replace/Lubricate
SMCS Code: 3279-040
Observe the driven equipment during operation. Look
for the following items:
• Unusual noise and vibration
Dampers Without Sampling Ports
• Loose connections
Some dampers do not have a port for a fluid sample.
These dampers must be rebuilt or the dampers must
be replaced when one of the following criteria has
been met:
• Damaged parts
• the damper has reached 20,000 hours of operation.
• the engine is undergoing a major overhaul.
Removal and Installation
Refer to the Disassembly and Assembly Manual,
“Vibration Damper - Remove and Install” article or
consult your Caterpillar dealer for information about
damper replacement.
Perform any maintenance that is recommended
by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the
following service instructions.
• Inspection
• Lubricating grease and lubricating oil requirements
• Specifications for adjustment
• Replacement of components
• Requirements for ventilation
SEBU7150-05
69
Maintenance Section
Engine Air Cleaner Element - Replace
i00453473
Engine Air Cleaner Element Replace
SMCS Code: 1051-510; 1054-510
Replace the Soot Filter
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
Unfiltered air will drastically accelerate internal engine
wear. The air silencer is wrapped in a disposable
soot filter. The soot filter helps prevent airborne dust
and debris from entering the air inlet. As the soot
filter becomes dirty, the air restriction increases.
Replace the soot filter when the air restriction reaches
3.75 kPa (15 inches of water).
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
1. Remove the used soot filter from the air silencer.
Discard the used soot filter.
2. Inspect the air silencer. Clean the air silencer, if
necessary.
3. Install a new soot filter.
i01421692
Engine Crankcase Breather Clean
SMCS Code: 1317-070
Clean the crankcase breather elements and replace
the O-ring seals at every oil change. Perform this
maintenance when the engine is stopped.
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
Illustration 55
(1)
(2)
(3)
(4)
(5)
g00745657
Breather assembly
Tee
Hose clamp
O-ring seal
Retaining clamp
1. Loosen hose clamps (3). Remove tee (2).
2. Loosen retaining clamps (5). Remove breather
assemblies (1) and O-ring seals (4).
3. Wash the breather elements in clean
nonflammable solvent. Inspect tee (2) for cracks
that can be caused by vibration. Replace the old
tee with a new tee if cracking is found.
4. Install new O-ring seals (4).
5. Allow the breather elements to dry before
installation. Install the breather assemblies in the
original position. Coat the rubber parts with clean
engine oil or petroleum jelly in order to make
installation easier.
6. Install the retaining clamps and the hose clamps.
See the Service Manual, “Specifications” module
for the proper torque.
i01903735
Engine Mounts - Check
SMCS Code: 1152-535
Check the condition of the isolators. The isolators
must be kept clean and dry. Ensure that the isolators
are free of oil and contamination.
70
Maintenance Section
Engine Mounts - Check
SEBU7150-05
Resilient Isolators
Illustration 56
Measure the Height of the Isolators
g00745665
Illustration 57
g00705353
(1) Rubber element
Each isolator has four rubber elements. The
most usual cause for failure of the isolator is oil
contamination of the rubber elements. Inspect the
rubber elements of each isolator for the following
conditions.
• Swelling
• Blistering
• Cracking
Perform the following procedures when deterioration
of the rubber elements is initially observed:
• Record the observation in a log.
• Check the alignment of the driven equipment.
After deterioration of the rubber elements is initially
observed, the rubber elements must be carefully
inspected. Any further deterioration of the rubber
elements must be recorded. The isolator must be
repaired or replaced if rapid deterioration of the
rubber elements is observed.
Deterioration of the rubber elements is usually
accompanied by settling of the isolator. Settling of
the isolator will result in misalignment between the
engine and the driven equipment.
Ensure that the covers are in the correct position and
that the O-rings are in good condition. This will help
prevent water from entering the top of the mount.
Water may cause the adjustment screw and/or the
locknut to seize.
There are two methods of measuring the heights of
the isolator:
Acceptable – This method does not take into
account deformation of the bed of the engine.
Measure the loaded height of each isolator. Use
an inside micrometer and measure dimension (A)
between the top of the soleplate and the bottom
of the engine support assembly. All measurements
must be taken at the location that was marked by the
manufacturer of the vessel at the time of the engine
commissioning.
Preferred – This is the most accurate method. This
method will ensure that each of the mounts are
carrying the same load. Measure each corner of each
isolator (B) and record the average height of the four
measurements from each isolator.
Compare the measurement to the height that is
stamped on the mounting foot of the engine or
compare the measurement to the specifications from
the report from the engine commissioning. If the
measurement has changed ± 1 mm (± 0.04 inch) from
the recorded height, the height of the mounting foot
must be adjusted back to the original specifications.
See this Operation and Maintenance Manual,
“Engine Mounts-Inspect” for information on adjusting
the engine mounts.
Note: It is important to keep accurate records of all of
the measurements so that trends can be developed
for the life of the isolators.
SEBU7150-05
71
Maintenance Section
Engine Mounts - Inspect
i01905152
Engine Mounts - Inspect
SMCS Code: 1152-040; 1152
Inspect the Center Bolt
Illustration 59
g00992217
(1) Jacking screw
(2) Setscrew
(3) Shim
1. Loosen setscrews (2).
Illustration 58
g00992208
(1) Locknut
(2) Adjustable assembly
(A) Clearance above the adjustable assembly
Inspect the tightness of locknut (1) on the center bolt.
Use a minimum torque of 220 N·m (162 lb ft).
If the locknut is loose, perform the following Steps:
1. Tighten the locknut to 220 N·m (162 lb ft).
2. Measure clearance (A) above adjustable assembly
(2).
3. Compare the clearance to the specification from
the engine commissioning. The clearance and
the specification from the engine commissioning
must be equal.
Any difference in the clearance indicates that the
height of the isolator has changed. A change in
the height of the isolator will result in misalignment
between the engine and the driven equipment.
Adjusting the Height Of the Engine
Support Assembly
Note: When shims are used in order to maintain the
height of the engine support assembly, the alignment
of the engine and the driven equipment must be
verified.
2. Raise the engine with jacking screw (1).
3. Add or remove shims (3), if necessary. Tighten
set screws (2).
Maintain a record of all of the shims that are added
and/or removed from each isolator. When any of
the following conditions occur the isolators must be
rebuilt or replaced:
• There is more than 5 mm (0.2 inch) of difference
between dimension (B) and the dimension that is
stamped on the mounting foot of the engine.
• Clearance (A) from illustration 58 can not be
adjusted to the required height.
For a standard rotation engine, the specification for
clearance (A) for the left side isolators is 9.5 mm
(0.4 inch). The specification for clearance (A) for the
right side isolators is 4.5 mm (0.2 inch).
For a reverse rotation engine, the specification for
clearance (A) for the left side isolators is 4.5 mm
(0.2 inch). The specification for clearance (A) for the
right side isolators is 9.5 mm (0.4 inch).
Note: If the isolators are repaired or replaced the
engine must be realigned with the driven equipment.
The new heights of the engine mounts must be
stamped on the mounting feet. A copy of the new
specifications must be added to the report from the
engine commissioning and/or ship’s documents.
For the proper adjustment, refer to the shipyard’s
installation manual.
72
Maintenance Section
Engine Oil Level - Check
SEBU7150-05
i02310009
Engine Oil Level - Check
SMCS Code: 1348-535-FLV
The most accurate check of the oil level is performed
when the engine is running at low idle and the lube oil
is warm. Perform this maintenance when the vessel
is as stationary as possible.
3. If necessary, remove oil filler cap (2) and add
oil. For the correct oil to use, see this Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
Do not fill the crankcase above “FULL” mark (4).
Clean the oil filler cap. Install the oil filler cap.
i01935337
Engine Oil Sample - Obtain
SMCS Code: 1348-554-SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
Illustration 60
g00745692
(1) Oil level gauge (dipstick)
(2) Oil filler cap
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
Illustration 61
g00992262
(3) “ADD” mark
(4) “FULL” mark
1. If the engine is not running, start the prelube
pump. If the engine is running, reduce the engine
speed to low idle.
2. Remove the oil level gauge. Observe the oil
level on the oil level gauge. Maintain the oil level
between the “ADD” mark (3) and the “FULL” mark
(4).
NOTICE
Operating the engine with the oil level above the
“FULL” mark could cause the crankshaft to dip into
the oil.
The air bubbles that are created by the crankshaft dipping into the oil reduces the lubricating characteristics
of the oil. This could result in the loss of power and
cause damage to the engine.
Do not overfill the engine with oil.
• Engine model
• Service hours on the engine
• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
SEBU7150-05
73
Maintenance Section
Engine Oil Temperature Regulator - Replace
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
For instructions, see Special Publication, PEHP6001,
“How To Take A Good Oil Sample”. Consult your
Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
i00839584
Engine Oil Temperature
Regulator - Replace
Replace the lubrication oil when oil analysis
determines that the oil has reached the condemning
limit.
In the absence of oil analysis, change the oil after
every 500 hours of operation.
Drain the Engine Oil
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact
skin.
NOTICE
Ensure that the engine is stopped before performing
this procedure. Attach a DO NOT OPERATE tag to the
starting controls.
Do not drain the oil when the engine is cold. As the
oil cools, suspended waste particles settle on the
bottom of the oil pan. The waste particles are not
removed when the cold oil is drained. Drain the
crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
oil to be drained properly.
SMCS Code: 1330-510
Failure to follow this recommended procedure will
allow the waste particles to be recirculated through
the engine lubrication system with the new oil.
The oil temperature regulators divert the engine
oil to the oil cooler in order to maintain engine oil
temperature.
1. After the engine has been operated at normal
operating temperature, STOP the engine.
For instructions on replacing the oil temperature
regulators, see the Service Manual, “Disassembly
and Assembly” module.
i02554249
Engine Oil and Filter - Change
SMCS Code: 1318-510
Oil Change Interval
The oil change interval is primarily determined by the
results of oil analysis. Other considerations include
the type of fuel, the lubrication oil, and the engine
application. When you establish an S·O·S oil analysis
program, you will be able to evaluate the used oil.
The evaluation can be used to determine if this oil
change interval is suitable for your specific engine.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
74
Maintenance Section
Engine Oil and Filter - Change
Illustration 62
SEBU7150-05
g00745694
2. Open drain valve (1) in order to drain used oil.
After the oil has drained, close drain valve (1).
If a suction device is used to drain the oil, ensure
that the suction device is clean in order to prevent
dirt from entering the oil pan. Be careful not to
strike the engine oil suction tubes or the piston
cooling jets.
Illustration 63
g00701472
1. Remove the bolts and washers from cover (1).
Remove cover (1) and the O-ring seal. Inspect
the seal for good condition. If the seal is cut,
scratched, or cracked, obtain a new seal for
assembly.
Note: After the used oil has been drained and before
the new oil is added, clean the oil suction screen.
Replace the engine oil filter elements.
Clean the Oil Suction Screen
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact
skin.
Clean the oil suction screen at every oil change.
Clean the oil suction screen after the oil sump has
been drained.
Note: Approximately 1 L (1 qt) of oil will remain in the
housing after the sump has been completely drained.
This oil will pour out of the housing when cover (1)
is removed. Catch the oil with a pan. Clean up any
spilled oil with absorbent pillows or towels. DO NOT
use absorbent particles to clean up the oil.
Illustration 64
g00745695
2. Slide screen assembly (2) from the tube.
3. Wash screen assembly (2) in clean nonflammable
solvent. Allow the screen assembly to dry before
installation.
4. Install screen assembly (2). Install cover (1) and
the O-ring seal. Secure the cover with the bolts
and washers.
Replace the Engine Oil filters
Replace the engine oil filters for any of the following
occurrences:
• Every oil change
• The engine oil filter differential pressure reaches
100 kPa (15 psi).
SEBU7150-05
75
Maintenance Section
Engine Oil and Filter - Change
Service tools are available to aid in the service of oil
filters and fuel filters. Consult your Caterpillar dealer
for the part names and the part numbers. Follow the
instructions that are supplied with the service tools. If
the service tools are not used, perform the following
procedure.
3. Be alert to the spring force. Cover (2) has a spring
force up to 240 N (54 lb). Gradually loosen but
do not remove the last two bolts or nuts that are
located at opposite corners of the cover. Before
removing the last two bolts or nuts, pry the cover
loose in order to relieve any spring pressure.
Hot oil and components can cause personal injury.
Do not allow hot oil or components to contact
skin.
Perform the following procedure after the oil sump
has been drained.
Illustration 66
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Illustration 65
g00745696
1. Connect a hose from each drain valve (1) to a
suitable container in order to catch the oil.
2. Open both drain valves (1). Allow the oil to drain.
Note: Some oil will remain in the housing after the oil
has been drained. This oil will pour out of the housing
when cover (2) is removed. Catch the oil with a pan.
Clean up any spilled oil with absorbent pillows or
towels. DO NOT use absorbent particles to clean up
the oil.
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
g00745697
Cover
O-ring seal
Spring
Retainer
O-ring seal
O-ring seal
Filter
4. Remove cover (2). Inspect O-ring seals (3),
(6), and (7) for good condition. If a seal is cut,
scratched, or cracked, obtain a new seal for
assembly.
5. Remove spring (4) and retainer (5).
6. Use a pan to catch the oil that drips when the
filters are removed. Remove the four used filters.
Clean up any oil that is spilled.
7. Clean cover (2), spring (4), and retainer (5).
8. Inspect four new filters for each housing for good
condition. Coat the sealing surfaces of the new
filters with clean engine oil. Install the filters into
the housing.
9. Install new O-ring seal (3) in the cover. Install new
O-ring seals (6) and/or (7) in the lower tube. Install
the lower tube into the cover. Cover the bores and
cover the seals with clean engine oil. Check the
location of O-ring seal (7) during installation of
the cover.
Note: The use of 2 guide pins will make installation
of the cover easier.
10. Install retainer (5), spring (4), and cover (2).
Ensure that the retainer and the spring are seated
properly against the filter and the cover. Secure
the cover with the bolts.
76
Maintenance Section
Engine Protective Devices - Check
11. Make sure that the drain valves on the covers
are closed.
Fill the Engine with Oil
1. Remove the oil filler cap. Fill the crankcase
through the oil filler tube only. Clean the oil filler
cap. Install the oil filler cap.
For the correct oil to use, see this Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
For the amount of oil to use, see this Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
SEBU7150-05
i01317223
Engine Protective Devices Check
SMCS Code: 7400-535
Calibration Check
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
2. Operate the prelube pump in order to fill both of
the oil filter housings with oil. Check the oil level
while the prelube pump is still running. Maintain
the oil level between the “ADD” and “FULL” marks
on the oil level gauge.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
devices are functioning properly.
3. Shut off the prelube pump. Start the engine.
Operate the engine at low idle rpm. Check the oil
level. Check for oil leaks.
NOTICE
During testing, abnormal operating conditions must be
simulated.
Inspect the Used Oil Filters
The tests must be performed correctly in order to prevent possible damage to the engine.
Cut the used oil filter open with a utility knife. Remove
the metal wrap. Cut the filter element free from the
end caps. Spread apart the pleats and inspect the
element for metal debris. An excessive amount of
debris in the element may indicate early wear or a
pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the element. Ferrous metals may indicate wear on
the steel and cast iron parts of the engine. Nonferrous
metals may indicate wear on the aluminum parts,
brass parts or bronze parts of the engine. Parts that
may be affected include the following components:
main bearings, rod bearings, turbocharger bearings,
and cylinder heads.
Due to normal wear and friction, it is not uncommon
to find small amounts of debris in the oil filter element.
If an excessive amount of debris is found in the oil
filter element, consult your Caterpillar dealer in order
to arrange for further oil analysis.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.
• For the calibration of temperature contactors, see
Special Instruction, SEHS9827, “Calibration of
Temperature Contactors”.
• For the calibration of pressure contactors, see
Special Instruction, SEHS9828, “Calibration of
Pressure Contactors”.
Consult your Caterpillar dealer or refer to the Service
Manual for more information.
SEBU7150-05
77
Maintenance Section
Engine Timing, Synchronization, and Valve Lash - Inspect/Adjust
Check the Magnetic Pickups
Check the Timing of the Crankshaft
and Camshaft
The timing of the crankshaft and camshaft must be
checked, and the valve bridge must be adjusted
before the valve lash is adjusted. The camshafts
must be correctly timed with the crankshaft before
the fuel timing is adjusted.
NOTICE
If the camshaft is rotated with the timing pin installed,
the timing pin will break. This can result in further damage. Make sure to remove the timing pin before the
camshaft is rotated.
Illustration 67
g00705318
(1) Magnetic pickup
(2) Flywheel ring gear
1. Clean the face of the magnet. Check the condition
of the magnetic pickup.
2. Measure the resistance of the magnetic pickup.
Resistance should be about 150 ohms.
3. If necessary, remove the magnetic pickup from
the flywheel housing.
Note: Some sensors have flat bottoms but other
sensors may have small tips. Ensure that the tip of
the sensor contacts the center point (highest point) of
the gear tooth.
4. Install the magnetic pickup in the flywheel housing.
Turn the magnetic pickup clockwise until the
magnet contacts a tooth of the flywheel ring gear.
5. Turn the magnetic pickup counterclockwise for 1
1/4 turns (450 degrees). Maintain a clearance of
1.41 to 1.76 mm (.0555 to .0693 inch) between
the magnetic pickup and the tooth of the flywheel
ring gear. Tighten the locknut to 45 ± 7 N·m
(33 ± 5 lb ft).
i01906035
Engine Timing,
Synchronization, and Valve
Lash - Inspect/Adjust
NOTICE
DO NOT use the starting motor to rotate the crankshaft. The lubrication oil can drain out from between
the crankshaft and the engine bearings if the engine
has not been operated for a period of time. Damage
can result if the crankshaft is rotated on dry bearing
surfaces.
To prevent damage to the crankshaft bearings, DO
NOT crank the engine before prelube, especially after
this maintenance procedure.
NOTICE
The prelube pump should not be operated continuously for extended periods of time. If, during repairs,
the prelube pump has run continuously for a period
of three hours or more, it will be necessary to remove
any oil that may have collected in the cylinders and/or
above the valves.
Prelube of the engine is required before the
crankshaft is rotated for normal maintenance.
Activate the prelube pump for rotating the engine
crankshaft.
NOTICE
Do not use an impact wrench to operate the barring
device. The use of an impact wrench will cause gear
tooth failure.
The barring device provides a means for slowly
turning the flywheel in order to service the engine.
The barring device can also be used to prevent
rotation of the crankshaft.
SMCS Code: 1102-040; 1105-535; 1290-040
For instructions on the following procedures, see
the Service Manual, “Systems Operation/Testing
and Adjusting”. Consult your Caterpillar dealer for
assistance.
Fuel Injector Timing (Fuel Timing)
The camshafts must be correctly timed with the
crankshaft before the fuel timing is adjusted. The
fuel timing dimension is stamped on the engine
Information Plate.
78
Maintenance Section
Engine Valve Rotators - Inspect
SEBU7150-05
Fuel Injector Clamp
The top surface of the clamp for the fuel injector must
be parallel to the top surface of the cylinder head.
Fuel Injector Synchronization
Synchronize the fuel injectors. When this
maintenance procedure is complete, ensure that
the barring device is disengaged from the flywheel
and ensure that the handle of the barring device is
secured in the disengaged position.
Valve Bridge
NOTICE
Do NOT attempt to adjust the valves if the crankshaft
and camshaft are not synchronized. Disregard for this
can result in engine damage such as bent valves.
Check the valve bridge and adjust the valve bridge,
if necessary. Perform the procedure for both valve
bridges for each cylinder.
After the valve bridge is satisfactory, check the valve
lash.
Engine Valve Lash
If the valve lash is within the tolerance, an adjustment
of the valve lash is NOT necessary.
The crankshaft and camshaft timing must be
checked, and valve bridge adjustment must be
performed before making a valve lash adjustment.
Perform the valve lash setting when the engine is
cold. After the engine has been shut down and the
valve covers are removed, the engine is considered
cold.
Before performing maintenance, prevent the entry of
foreign matter into the top of the cylinder head and
the valve mechanism. Thoroughly clean the area
around the valve mechanism covers.
i01765711
Engine Valve Rotators - Inspect
SMCS Code: 1109-040
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
Note: Use of a platform may be necessary to reach
the engine valve rotators.
Perform this procedure after the valve lash has been
set.
1. Mark the tops of the valve rotators with a
permanent marker. Note the position of the marks.
2. Install the valve covers. See the Service Manual
for the procedure.
3. Start the engine. Operate the engine for 5 minutes.
Stop the engine.
4. Remove the valve covers. Observe the position of
the marks that are on the valve rotators.
If a valve fails to rotate, consult your Caterpillar
dealer.
i00746289
Exhaust Shields - Inspect
SMCS Code: 1067-040
Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
SEBU7150-05
79
Maintenance Section
Fuel Analysis - Obtain
NOTICE
The insulation for the exhaust system can be damaged if work is performed on the insulation or around
the insulation.
Do not tear the surface of the insulation. A torn surface
will allow the insulation to absorb flammable liquids
and a fire can result from engine heat.
Remove the insulation or protect the insulation before
performing work on the insulation or around the insulation. Handle the insulation carefully.
Ensure that the exhaust manifold is cool. Inspect
the insulation for the exhaust system. Replace any
insulation that is damaged. Consult your Caterpillar
dealer for assistance.
The reports may indicate variations within the
fuel. If the reports are inconsistent, obtain another
analysis of the fuel. This will eliminate the
possibility of testing error.
4. Compare the reports to Special Publication,
SEBU7003, “3600 Series and C280 Series Diesel
Engine Fluids Recommendations”.
If the fuel does not meet the minimum
requirements, deposits and/or corrosion could
cause excessive wear on the fuel system and/or
failure of the fuel system.
Clean fuel that meets the fuel recommendations will
help ensure rated engine performance and maximum
engine service life.
i01317685
i02355562
Fuel Analysis - Obtain
Fuel System - Prime
SMCS Code: 1250-548; 1258-548
SMCS Code: 1280-554
To ensure optimum performance of the engine, obtain
a complete fuel analysis when fuel is delivered.
Obtain the analysis before using the fuel.
1. Ask the supplier of the fuel for the fuel
specifications.
2. Obtain samples of the fuel.
Note: If a fuel supply is delivered to the site by trucks,
obtain samples from approximately five percent of
the supply tanks.
a. Submit a sample of the fuel immediately to an
independent laboratory for analysis.
The fuel analysis must include all of the
properties that are listed in Special Publication,
SEBU7003, “3600 Series and C280 Series
Diesel Engine Fluids Recommendations”.
b. Retain samples of the fuel in case future
analysis is needed.
Label the samples accurately for future
identification. The samples may be needed
for future analysis if questions about quality,
stability, or compatibility arise.
3. Compare the supplier’s report to the report from
the analysis.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
Prime the fuel system in order to fill dry fuel filters
and purge air from the fuel system. Prime the fuel
system after the following occurrences:
• The fuel filter elements are replaced.
• The engine is run dry.
• The fuel lines have been disconnected.
• The engine has been overhauled.
• The engine is removed from storage.
80
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
SEBU7150-05
i02310947
Fuel System Primary Filter
(Water Separator) Element Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Illustration 68
g00366372
Vent plugs for the fuel filters
1. Open the vent plugs for the fuel filters.
2. Operate the fuel priming pump of the vessel until
fuel appears at the openings of the vent plugs.
Operate the priming pump until the fuel flows
free of air bubbles. Clean up any spilled fuel
immediately.
3. Tighten the vent plugs.
Priming the Fuel System After
Disconnecting Fuel Lines or After
an Overhaul
1. Loosen the connector that is above the fuel
pressure regulator valve. Use a cloth to catch any
fuel and clean up any fuel that overflows.
2. Operate the fuel priming pump of the vessel until
fuel appears at the opening of the connector.
Operate the priming pump until the fuel flows
free of air bubbles. Clean up any spilled fuel
immediately.
3. Tighten the connector that is above the fuel
pressure regulator valve.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
Replace the element of the primary filter/water
separator according to the instructions that are
provided by the OEM of the primary filter/water
separator.
Note: It may be necessary to prime the fuel system
before the engine will start. See this Operation and
Maintenance Manual, “Fuel System - Prime” topic
(Maintenance Section).
i00744357
Fuel System Primary
Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
Drain the primary filter/water separator on a daily
basis before starting the engine.
For specific instructions for draining the primary
filter/water separator, see the service information that
is provided by the OEM of the primary filter/water
separator.
SEBU7150-05
81
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel
system.
i02553920
Fuel System Secondary Filter Replace
SMCS Code: 1261-510-SE
Illustration 69
Replace the secondary fuel filter elements when
either of the following conditions occur:
• The engine is operating at rated speed and at
operating temperature and the fuel filter differential
pressure reaches 69 kPa (10 psi).
• The fuel filter elements have been used for 1000
hours of operation.
(1)
(2)
(3)
(4)
g00745778
Control valve
Drain valve
Vent plug
Cover
1. Stop the engine. Connect one end of a hose to
each drain valve (2). Insert the other end of the
hoses into a suitable container in order to catch
the fuel.
Service tools are available to aid in the service of oil
filters and fuel filters. Consult your Caterpillar dealer
for the part names and the part numbers. Follow the
instructions that are supplied with the service tools. If
the service tools are not used, perform the following
appropriate procedure.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
Replacing the Secondary Filters
With the Engine Stopped
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
2. Remove both vent plugs (3). Open both drain
valves (2) in order to drain the secondary fuel
filters.
Note: If the fuel filter is installed vertically, then the
drain valves are in the bottom.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Personal injury can result from parts and/or covers under spring pressure.
Spring force will be released when covers are removed.
Be prepared to hold spring loaded covers as the
bolts are loosened.
82
Maintenance Section
Fuel System Secondary Filter - Replace
SEBU7150-05
Note: Some fuel will remain in the housing after the
fuel has been drained. This fuel will pour out of the
housing when cover (4) is removed. Catch the fuel
with a pan. Clean up any spilled fuel with absorbent
pillows or towels. DO NOT use absorbent particles
to clean up the fuel.
3. Be alert to the spring force. Gradually loosen but
do not remove the last two bolts or nuts that are
located at opposite corners of cover (4). Before
removing the last two bolts or nuts, pry the cover
loose in order to relieve any spring pressure.
10. Make sure that the drain valves on the covers are
closed. Clean vent plugs (3). Install the vent plugs
loosely. Prime the fuel system. See this Operation
and Maintenance Manual, “Fuel System - Prime”
topic (Maintenance Section).
11. Start the engine and check for fuel leaks.
Replacing the Secondary Filters
During Engine Operation
Filter contains hot pressurized fluid when engine
is running.
Follow instructions on control valve to avoid personal injury.
If rapid air movement exists to blow fluid, Stop the
engine to avoid fire.
Illustration 70
(4)
(5)
(6)
(7)
(8)
(9)
g00745776
Cover
O-ring seal
Spring
Retainer
Rack
Filter
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
4. Remove cover (4) and O-ring seal (5). Inspect the
seal for good condition. If a seal is cut, scratched,
or cracked, obtain a new seal for assembly.
5. Remove spring (6) and retainer (7).
6. Filters (9) are loaded on wire rack (8) that is inside
of the housing. Remove wire racks (6). Use a
pan to catch the fuel that drips when the rack
and filters are removed. Remove the used filters.
Clean up any fuel that is spilled.
7. Clean cover (4), spring (6), and retainer (7). Clean
rack (8) and clean the inside of the housing.
8. Inspect 4 new filters for each housing for good
condition. Coat the sealing surfaces of the new
filters with clean diesel fuel. Place the filters onto
rack (8). Install the filters and the rack into the
housing.
9. Install retainer (7), spring (6), cover (4) and O-ring
seal (5). Ensure that the retainer and the spring
are seated properly against the filter and the
cover. Secure the cover with the bolts.
Illustration 71
(1)
(2)
(3)
(4)
g00745778
Control valve
Drain valve
Vent plug
Cover
1. To service the lower secondary fuel filter, turn
control valve (1) to the “UPPER RUN” position.
2. Connect one end of a hose to drain valve (2).
Insert the other end of the hose into a suitable
container in order to catch the fuel.
SEBU7150-05
83
Maintenance Section
Fuel Tank Water and Sediment - Drain
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
3. Remove vent plug (3). Open drain valve (2) in
order to drain the secondary fuel filter.
4. Perform Steps 3 through 9 from “Replacing the
Secondary Filters With the Engine Stopped”.
5. Close drain valve (2). Clean vent plug (3). Install
the vent plug loosely. Slowly turn control valve (1)
to the “LOWER FILL” position. After five minutes,
turn control valve (1) to the “BOTH RUN” position.
Tighten vent plug (3).
6. To service the upper secondary fuel filter, turn
control valve (1) to the “LOWER RUN” position.
Perform Steps 1 through 5 for the upper secondary
fuel filter.
7. After both of the secondary fuel filters have been
serviced, turn control valve (1) to the “BOTH RUN”
position.
Drain the water and sediment from the day tank daily.
The quality of the fuel or the operating conditions
may require the water and sediment to be drained
more often.
Fill the day tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
Some day tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some day tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks
Drain the water and the sediment from the fuel
storage tank daily. Ensure that the water and
sediment is drained from the fuel storage tank when
the tank is refilled. This will help prevent water and/or
sediment from being pumped from the fuel storage
tank into the engine fuel tank.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
i00746380
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
Day Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the day tank. This
causes water to accumulate in the day tank. Draining
the day tank regularly and obtaining fuel from reliable
sources can help to eliminate water from the fuel.
Day tanks should have a provision for draining water
and sediment.
Open the drain valve on the bottom of the day tank
in order to drain the water and the sediment. Close
the drain valve.
i01917123
Governor Actuator Linkage Check
SMCS Code: 1265-535
Check the governor actuator linkage for proper
operation. For the procedure to adjust the actuator
linkage, see the Service Manual, “Systems
Operation/Testing and Adjusting”.
i01906057
Metal Particle Detector Inspect
SMCS Code: 7400-040
If the metal particle detector causes a shutdown,
inspect the detector.
84
Maintenance Section
Oil Mist Detector - Maintain
SEBU7150-05
i01421138
Oil Mist Detector - Maintain
SMCS Code: 1336-042
NOTICE
The engine can be severely damaged by excessive oil
mist.
To help ensure proper operation of the oil mist detector, perform the recommended maintenance on the
detector.
Illustration 72
g00745503
Metal particle detector
(1) Cover
1. Use a 1/2 inch ratchet to remove cover (1) and the
O-ring seal from the detector.
Failure to perform the recommended maintenance
for the oil mist detector can allow these possible
effects on the operation of the detector:
• Inability to activate an alarm for excessive oil mist
• Activation of faults in the detector
2. Remove the grid and the O-ring seal for the grid
from the inside of the detector.
• Activation of false alarms for excessive oil mist
3. If metal particles are found, determine the source
of the particles. Make repairs, as needed.
Perform the maintenance procedures for the oil
mist detector according to the instructions in
Service Manual, RENR2225, “Oil Mist Detectors”.
NOTICE
Metal particles in the lube oil may indicate a serious
condition that requires immediate attention.
If metal particles are found in the grid of the detector,
do not start the engine until the source of the particles
is found and the condition is corrected. Failure to do
so could cause severe damage to the engine.
4. Clean the inside of the detector and clean the grid
with nonflammable solvent.
Note: To replace the O-ring seals and the grid, use
the 165-5690 Particle Detector Kit.
5. Inspect the grid and the O-ring seals for good
condition. Obtain new parts, if necessary.
6. Install the clean, dry grid and the O-ring seal for
the grid.
7. Install the cover and the O-ring seal for the cover.
Torque the cover to 54 N·m (40 lb ft).
The regular maintenance that is required for the oil
mist detector is listed in Table 22.
Note: The intervals for performing the maintenance
are provided as guidelines. Particular installations
may require more frequent maintenance intervals.
SEBU7150-05
85
Maintenance Section
Overhaul (Major)
Table 22
Maintenance Schedule for the Oil Mist Detector
Interval
Maintenance Procedure
When Required
Perform all of the following maintenance after the vessel has been in storage:
Daily
Maintain the system for the compressed air.
Every Month
Check the pressure of the vacuum in the measuring head. Adjust the pressure, if necessary. (1)
Clean the box for the oil drain (if equipped).
Every 3 Months
Perform the following maintenance on these items in the measuring head:
Clean the bores for the filtered air.
Replace the sintered bronze filters.
Clean the glass of the infrared filters.
Every Year
Replace the sintered bronze filter for the pressure regulator.
Clean the suction lines for sampling the atmosphere from the crankcase.
Clean the oil drain line.
(1)
When this procedure is performed after Every Three Months, perform this procedure last.
i02539152
Overhaul (Major)
SMCS Code: 7595-020-MJ
The need for a major overhaul is determined by
several factors.
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease and variation of cylinder compression
Other factors must also be considered for determining
a major overhaul:
• The total amount of fuel consumption
• The service hours of the engine
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration
An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
require service.
Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
the wear metals.
Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
A major overhaul includes all of the work that is done
for top end overhauls. A major overhaul includes
additional parts and labor. Additional parts and labor
are required in order to completely rebuild the engine.
For the major overhaul, all of the bearings,
seals, gaskets, and components that wear are
disassembled. The parts are cleaned. The parts are
inspected. If necessary, the parts are replaced. The
crankshaft is measured for wear. The crankshaft may
require regrinding. Alternatively, the crankshaft may
be replaced with a Caterpillar replacement part.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.
The following definitions explain the terminology for
the services that are performed during an overhaul:
86
Maintenance Section
Overhaul (Major)
SEBU7150-05
Inspect – Inspect the components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
(Table 23, contd)
Recommendations for the Major Overhaul
Service
Replace
Recommendations for the Major Overhaul
Service
Rebuild
Component
(1)
Connecting rod bearings
(2)
Cylinder head valves and valve guides
Cylinder head valve spring guides
Exhaust manifold bellows
Exhaust shields
Front gear train bearings (3)
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer for a
credit on replacement parts. Consult your Caterpillar
dealer about repair options for your engine.
Table 23
Accessory group bearings
Camshaft bearings
Rebuild – The component is reconditioned in order
to comply with reusability guidelines.
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
recommendations in Table 23.
Component
Fuel injectors
Main bearings
(2)
Oil pump bearings
Oil temperature regulators
Turbocharger bearings and bushings
Water pump bearings
Water temperature regulators
Inspect
Aftercooler cores
Alarm and shutoff controls
Camshafts
(1) (4)
Crankshaft
(2) (4)
Cylinder block
Centrifugal oil filters
Cylinder liners
Cylinder heads
Cylinder sleeves
Starting motor
Exhaust manifolds
Vibration damper
Front gear group
(continued)
(3)
Oil cooler
Oil pump bushings
Oil suction screen
Pistons and piston rings
Priority valve
Rear gear group
(3)
Rear gear train bearings
(3)
Rocker arm bearings
Thermocouples
Thrust bearings
Valve mechanism group
(continued)
SEBU7150-05
87
Maintenance Section
Overhaul (Top End)
(Table 23, contd)
i02723990
Recommendations for the Major Overhaul
Service
Replace
the gaskets
and seals
of these
components.
Component
Air inlet lines
Camshaft front covers
Camshaft drive gear covers
Central structure covers
Crankcase side covers
Crankshaft
Overhaul (Top End)
SMCS Code: 7595-020-TE
The overhaul interval that is listed in this Operation
and Maintenance Manual, “Maintenance Interval
Schedule” is expressed in fuel consumption and
service hours. The more accurate figure to use is fuel
consumption. Fuel consumption corresponds more
accurately to the engine load.
(5)
Crankshaft vibration damper
Cylinder heads
Exhaust manifold
Front housing group
Table 24 lists an average range of fuel consumption
for a reasonable load factor before a top end
overhaul. Use the range of fuel consumption only as
a guideline.
Table 24
Approximate Fuel Consumption Before A
Top End Overhaul
Fuel lines
Fuel transfer pump
Engine
Model
Gear inspection group
Oil cooler
Oil lines
Oil temperature regulators
O-ring seals and plugs
Power take-off covers
Priority valve group
Rear gear train
Rear housing group
Rear structure covers
Turbocharger
Valve covers
Water lines
Water pumps
Water temperature regulators
3618
(1)
Fuel Consumption
(1)
12 605 000 to 14 763 000 L
3 330 333 to 3 900 000 US gal
The fuel consumption is based on fuel with a low heat value
of 42 780 kJ/kg and density of 838.9 g/L.
A top end overhaul involves the removal, the
inspection, and the rework of the cylinder head
components. Some additional components are
replaced and serviced.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
The following definitions explain the terminology for
the services that are performed during an overhaul:
(1)
Inspect the camshaft for damage to the journals and the lobes.
Inspect the camshaft bearings and the camshaft followers for
signs of wear and/or scuffing.
(2) Inspect the crankshaft for these conditions: deflection, damage
to the journals, and bearing material that has seized to the
journals. Inspect the profile and the taper of the crankshaft
journals. Compare the crankshaft journals to the wear patterns
in the connecting rod bearings and the main bearings.
(3) Inspect the gears and the bushings of the gear trains for worn
gear teeth, unusual fit, and unusual wear.
(4) If the crankshaft or the camshaft are removed for any reason,
use the magnetic particle inspection process to check for
cracks.
(5) Inspect the area around the front seal and the rear seal of the
crankshaft. It is not necessary to replace a crankshaft seal if
the seal is not leaking.
Inspect – Inspect the components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
Rebuild – The component is reconditioned in order
to comply with reusability guidelines.
88
Maintenance Section
Overhaul Considerations
SEBU7150-05
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer for a
credit on replacement parts. Consult your Caterpillar
dealer about repair options for your engine.
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
recommendations in Table 25.
Table 25
(Table 25, contd)
Recommendations for the Top End Overhaul
Service
Replace
the
gaskets
and
seals.
(1)
Component
Exhaust Bypass Valve
The angles of the valves and the seats are different. If the
valves and the seats are not replaced, lap the valves and the
seats. The valve and the outer diameter of the seat must have
360 degrees of contact. If the valves and the seats require
grinding, see the Service Manual, “Specifications” for the
angles.
Recommendations for the Top End Overhaul
Service
Inspect
Replace
i02301217
Component
Cylinder sleeves
Overhaul Considerations
Exhaust shields
SMCS Code: 7595-043
Starting motor
Turbocharger bearings, bushings, and seals
Clean
Inspect
Rebuild
Cylinder
heads
An overhaul is replacing the major worn components
of the engine. An overhaul interval is a maintenance
interval that is planned. The engine is rebuilt with
certain rebuilt parts or new parts that replace the
worn parts.
Oil cooler core
Oil suction screen
Exhaust valves
(1)
Exhaust valve seat inserts
Inlet valves
An overhaul also includes the following maintenance:
(1)
Inlet valve seat inserts
• Inspection of all the parts that are visible during
the disassembly
Inner valve springs
Outer valve springs
• Replacement of the seals and gaskets that are
removed
Valve spring guides
Valve spring locks
• Cleaning of the internal passages of the engine
and the engine block
Valve rotators
Replace
Overhaul Information
Cylinder head gaskets
Most owners will save money by overhauling the
engine at the intervals that are recommended in this
Operation and Maintenance Manual. Consider the
graph in Illustration 73.
Exhaust manifold gaskets
Fuel injectors
Fuel transfer pump seals
Oil pump bearings and seals
Oil temperature regulators and seals
O-ring seals and plugs
Seals for the inlet air lines
Water pump bearings and seals
Water temperature regulators and seals
(continued)
SEBU7150-05
89
Maintenance Section
Overhaul Considerations
• Achieve the best cost/value relationship per hour
of extended service life.
Overhaul Intervals
Some factors that are important for determining
the overhaul intervals include the following
considerations:
• Performance of preventive maintenance
• Use of recommended lubricants
• Use of recommended coolants
Illustration 73
g00745964
(Y) Cost
(X) Time
(1) Cost of maintenance and repair that is planned
(2) Cost of maintenance and repair that is not planned
In Illustration 73, line (1) represents the maintenance
and repair costs for an owner that followed the
recommendations for inspection, maintenance, and
repair. The peaks represent overhauls.
Line (2) represents the maintenance and repair
costs for an owner that chose to operate beyond
the recommended intervals. The initial cost of the
“repair-after-failure” philosophy is lower. Also, the
first overhaul was delayed. However, the peaks are
significantly higher than the peaks for the customer
that used the “repair-before-failure” philosophy .
• Use of recommended fuels
• Proper installation
• Operating conditions
• Operation within acceptable limits
• Engine load
• Engine speed
Generally, engines that are operated at a reduced
load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
properly operated and maintained.
The higher peaks result from two key factors:
Other factors must also be considered for determining
a major overhaul:
• Delaying an overhaul until a breakdown increases
• The total amount of fuel consumption
the chance of a catastrophic failure. This type of
failure requires more parts, labor, and cleanup.
• Excessive wear means that fewer components
will be reusable. More labor may be required for
salvage or repair of the components.
• The service hours of the engine
• An increase of oil consumption
• An increase of crankcase blowby
When all of the costs are considered,
“repair-before-failure” is the least expensive
alternative for most components and engines.
• The wear metal analysis of the lube oil
It is not practical to wait until the engine exhibits
symptoms of excessive wear or failure. It is not less
costly to wait. A planned overhaul before failure may
be the best value for the following reasons:
An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
require service.
• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the
guidelines for reusable parts.
• The service life of the engine can be extended
without the risk of a major catastrophe due to
engine failure.
• An increase in the levels of noise and vibration
Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
the wear metals.
90
Maintenance Section
Overhaul Considerations
Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Using Fuel Consumption For Calculating the
Overhaul Intervals
The total fuel consumption is the most important
factor for estimating the overhaul interval. Fuel
consumption compensates for the application and
for the engine load.
If the total fuel consumption has not been recorded,
use the equation in Table 26 in order to estimate the
hours until the overhaul. The equation may also be
used to estimate overhaul intervals for new engines.
Table 26
Equation For Calculating Overhaul Intervals
H = F/R
“H” is the number of estimated hours until the overhaul
interval.
“F” is the estimated total amount of fuel consumption of
the engine.
“R” is the rate of fuel consumption in liters per hour or
gallons per hour.
Use the actual records of fuel consumption, when
possible. If the actual records are not available, use
the following procedure in order to estimate the fuel
consumption.
1. Estimate the average percent of the load for the
operation of the engine.
2. Refer to the engine’s Caterpillar, “Engine
Specifications” (“spec” sheet). This will determine
the fuel consumption for the percent of the load
that was estimated in Step 1. Use this figure for
the equation in Table 26.
Oil Consumption as an Overhaul Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
SEBU7150-05
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
When an engine’s oil consumption has risen to
three times the original oil consumption rate due
to normal wear, an engine overhaul should be
scheduled. There may be a corresponding increase
in blowby and a slight increase in fuel consumption.
Overhaul Inspection
Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order
to perform the required maintenance on the items
that are listed. Consult your Caterpillar dealer for
assistance.
To determine the reusability publications that are
needed to inspect the engine, refer to Guidelines for
Reusable Parts and Salvage Operations, SEBF8029,
“Index of Publications on Reusability or Salvage of
Used Parts”.
The Guidelines For Reusable Parts and Salvage
Operations is part of an established Caterpillar
parts reusability program. These guidelines were
developed in order to assist Caterpillar dealers and
customers reduce costs by avoiding unnecessary
expenditures for new parts. If the engine parts comply
with the established inspection specifications, the
parts can be reused.
The use of out-of-spec parts could result in
unscheduled downtime and/or costly repairs. The use
of out-of-spec parts can also contribute to increased
fuel consumption and reduction of engine efficiency.
New parts are not necessary if the old parts can be
reused, repaired, or salvaged. Otherwise, the old
parts can be replaced or exchanged.
Your Caterpillar dealer can provide the parts that are
needed to rebuild the engine at the least possible
cost.
Overhaul Programs
An economical way to obtain most of the parts
that are needed for overhauls is to use Caterpillar
remanufactured parts. Caterpillar remanufactured
parts are available at a fraction of the cost of new
parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
examples of the remanufactured parts:
• Cylinder heads
• Oil Pumps
SEBU7150-05
91
Maintenance Section
Starting Motor - Inspect
• Turbochargers
• Water pumps
Consult your Caterpillar dealer for details and for a
list of the remanufactured parts that are available.
Your Caterpillar dealer may be offering a variety of
overhaul options.
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on
preventive maintenance programs or major repair
options are available from many servicing dealers
for all Caterpillar Engines. Consult your Caterpillar
dealer in order to schedule a before failure overhaul.
Overhaul Recommendation
Caterpillar recommends a scheduled overhaul in
order to minimize downtime. A scheduled overhaul
will provide the lowest cost and the greatest value.
Schedule an overhaul with your Caterpillar dealer.
Overhaul programs vary between dealers. To obtain
specific information about the types of overhaul
programs and services, consult your Caterpillar
dealer.
i01913789
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
More frequent inspection and replacement of the
starting motor may be required for the following
conditions:
• Operation in harsh environments
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
teeth of the starter motor pinion and the flywheel ring
gear. Look for patterns of wear on the teeth. Look for
teeth that are broken or chipped. If damaged teeth
are found, the starter motor pinion and the flywheel
ring gear must be replaced.
Inspect all of the components in the air circuit for
the starting motor. Inspect all of the air lines and
connections for leaks.
Remove the air starting motors for inspection.
Overhaul the air starting motors. Refer to the
Service Manual or consult your Caterpillar dealer for
instructions on removing and on overhauling the air
starting motors.
i01426751
Trend Data - Record
SMCS Code: 1000-043
Records of engine performance are an important
element of a maintenance program. The data on
engine performance can help to predict problems
with operation. Also, the data can provide information
that is useful for achieving optimum operation.
Traditionally, data on engine performance might be
recorded regularly. However, the data might not be
reviewed until the occurrence of a problem. This
method of monitoring engine operation has several
disadvantages:
• The engine may not be providing optimum
performance. This may not be noticed because
the engine does not exhibit excessive changes in
performance.
• Applications that require frequent stops and starts,
• Because a problem occurs, the engine may be in
If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of
the starting motor is recommended.
• Repairs may cause more downtime.
such as the operation of a fast ferry
The starter motor pinion and the flywheel ring gear
must be in good condition in order for the engine to
start properly. The engine will not start if the starter
motor pinion does not engage the flywheel ring gear.
The teeth of the starter motor pinion and the flywheel
ring gear can be damaged because of irregular
engagement.
an alarm condition that requires a quick response.
• The cost of downtime is compounded by the cost
of parts and labor for repairs.
The absence of an alarm condition does NOT
guarantee normal operation. Not all parameters
have alarms and/or shutdowns. Setpoints for alarms
are outside of the normal ranges in order to avoid
occasional nuisance warnings. An alarm indicates a
serious condition that requires immediate attention.
Service or repair is a reaction to an alarm condition.
A different approach is necessary in order to
schedule service before an alarm condition occurs.
Monitor the trends of the engine’s performance.
The following benefits can be realized:
92
Maintenance Section
Trend Data - Record
• Reduction of engine performance will be noticed
sooner.
• Problems can be predicted. This enables
prevention of the problems. Service can be
planned before an alarm condition occurs.
• Planning for downtime will also reduce downtime.
• The cost of parts and labor for service that is
planned will be less than the cost of repairs that
are not anticipated.
Monitoring the Trends of Engine
Performance
For marine applications, the power demand can be
difficult to determine. Consider the following factors
for determining the power demand:
• For propulsion with a water jet or a fixed propeller,
the theoretical power is approximately proportional
to the cubed engine speed.
• Power demand at a given engine speed is
dependent on several factors: loading of the
vessel, weather, design of the hull, and other
conditions.
To maintain a program for monitoring that is
successful, several factors are important:
• Record the data regularly when the engine is
operating at similar loads and speeds.
SEBU7150-05
• Use the data from the engine commissioning.
The data is recorded for various loads. The data
is recorded before any wear or deterioration
takes place.
• If there is no data from the engine
commissioning, use data from the engine test
cell. Understand that the data will not be specific
to the site.
• If data is not available from the engine
commissioning or the engine test cell, calculate
an average of the existing data.
• Establish a new baseline after an overhaul.
2. Frequently record the new data during engine
operation. For an example of a log to use,
see this Operation and Maintenance Manual,
“Hourly Performance Log” (Reference Information
Section).
Be aware that the readings of some parameters
depend on the engine load. Record the data
when the engine is operating at a high load. This
increases the accuracy of the data. Also, any
reduction in performance will be revealed sooner.
A load of 75 to 100 percent is recommended.
• For operations with a consistent load cycle,
record the data at the same time for each day.
• If the load can be controlled, set the load to the
same amount for each reading.
• At regular intervals, review the data in a graphic
Some parameters that are NOT affected by the
load ARE affected by the engine rpm. Obtain the
readings for these parameters when the engine is
operating at the same rpm.
• Perform corrections before damage and/or
Some parameters are not affected by either the
load or the rpm. See Table 27.
• Obtain accurate data.
format.
downtime occurs.
Accurate data is provided by accurate instruments
and proper use of the instruments. The gauges and
the sensing devices must be in good condition. This
is especially true for thermocouples. Establish a
program for calibrating the instruments periodically.
Avoid using infrared thermometers for obtaining
data. Be sure to read the gauges properly. Accurate
recording of the data is also important.
Use the following Steps to establish a program.
1. Establish a baseline for the engine parameters.
The baseline is necessary in order to know the
normal gauge readings. The new data will be
compared to the baseline.
SEBU7150-05
93
Maintenance Section
Trend Data - Record
Table 27
Parameters of Engine Operation
Parameters That Depend On the Load
Aftercooler and oil cooler water temperature (outlet)
Cylinder pressure
Crankcase pressure
Exhaust manifold pressure
Exhaust manifold temperature
Exhaust port temperature
Inlet air restriction
Inlet air temperature
Inlet manifold air pressure (boost pressure) (1)
Inlet manifold air temperature (1)
Outlet temperature of the jacket water
Parameters That Depend On the RPM
Fuel filter differential pressure
Fuel pressure
Jacket water pressure
Lube oil pressure
Oil filter differential pressure
Parameters That Are Independent of the
Load and RPM
Aftercooler and oil cooler water temperature (inlet)
Inlet temperature of the jacket water
Lube oil temperature
(1)
This includes the air before the aftercooling and after the
aftercooling.
Note: A gauge reading that is abnormal may indicate
a problem with operation or a problem with the gauge.
Illustration 74
g00747475
Example of a graph of engine oil pressure
(Y) Pressure in kPa
(X) Calendar days
(1) Baseline
(2) Operating pressure
(3) Setpoint (alarm)
3. Average the data for each day. Use a computer
or graph paper in order to produce a graph of
the data. Compare the new data to the baseline.
This will help to reveal the trends of the engine
performance.
Illustration 74 shows that the engine oil pressure
was near baseline (1). Later, the operating
pressure was approaching setpoint (3). The
trend of operating pressure (2) indicated that the
condition required investigation before activation
of the alarm.
4. Compare the new data to the data from previous
months. This comparison will be useful for
scheduling reconditioning for the engine.
Monitoring the Trends of Oil
Consumption
The consumption of lube oil depends on the following
factors:
• Engine load
• Hours of operation
• Type of oil
Monitor the engine’s oil consumption by calculating
the Specific Oil Consumption on a daily basis. Be
aware that the following conditions can produce
misleading data on oil consumption:
• Improper operation of the lube oil centrifuge
• Inaccurate measurement of additions of oil
• Leaking of lube oil
94
Maintenance Section
Turbocharger - Inspect
SEBU7150-05
• Overfilling of the oil sump
To measure additions of oil accurately, use a meter to
monitor additions of oil at the engine. Also, check the
total oil consumption against the delivery of oil.
Calculating Specific Oil Consumption
Use the equation that is in Table 28 in order to
calculate the Specific Oil Consumption.
Table 28
Equation For Calculating the Specific
Oil Consumption
O × D
bkW-hr
= BSOC
D is the density of the oil. The density is expressed in
grams per liter.
bkW-hr is the kilowatt hours that have been produced
during consumption of the oil.
BSOC is the brake specific oil consumption. This is
expressed in grams per kilowatt hour.
To calculate the BSOC, the bkW-hr must be known.
Table 29 is an example for calculating the bkW-hr.
The data in the example assumes the following
conditions:
• A meter was used to measure the fuel consumption
of 1000 liters.
• The density of the fuel sample is 980 grams per
liter.
• One kilowatt hour per 200 grams of fuel is the
average estimate. This is based on Brake Specific
Fuel Consumption (BSFC) for various engine loads
and for various operating conditions.
Table 29
Example for the Calculation of Kilowatt Hours
1
×
980g
L
×
bkW-hr
200g
=
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine
cylinder. This can cause additional damage to the
pistons, the valves, and the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
O is the liters of oil that have been consumed.
1000L
Fouling of the compressor can contribute to loss of
engine power, increased black smoke and overall
loss of engine efficiency.
9,800 bkW
i01911953
Turbocharger - Inspect
SMCS Code: 1052-040
Periodic inspection and cleaning is recommended for
the turbocharger compressor housing (inlet side).
Minor leakage of a turbocharger housing under extended low idle operation should not cause problems
as long as a turbocharger bearing failure has not occurred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
Note: Turbocharger components require clearances
that are precise. The turbocharger cartridge
must be balanced due to high rpm. Severe
service applications can accelerate the wear of the
components. Severe service applications may require
more frequent inspections of the turbocharger.
Removal and Installation
For options regarding the removal and installation
of the turbocharger, refer to Service Manual,
RENR1335, “3618 Engine” or consult your Caterpillar
dealer. For repair instructions, refer to Operation
and Maintenance Manual, SEBU7642, “TPL 65
Turbocharger” or consult your Caterpillar dealer.
Cleaning and Inspecting
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
SEBU7150-05
95
Maintenance Section
Walk-Around Inspection
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication
of contact between the rotating turbine wheel
or the turbocharger wheel and the turbocharger
housing, the turbocharger should be reconditioned
or replaced.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
turbocharger to slobber.
4. Inspect the bore of the turbine housing for
corrosion.
5. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
6. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
i00528664
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, thoroughly inspect
the engine compartment before starting the engine.
Look for items such as leaks, loose bolts, loose
connections and trash buildup. Make repairs, as
needed.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
• Ensure that cooling lines are properly clamped and
tight. Check for leaks. Check the condition of all
pipes.
• Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur when the engine cools and the
parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
• Drain the water and the sediment from fuel tanks
on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection and
for good condition.
• Check the condition of the gauges. Replace any
gauge that is damaged. Replace any gauge that
can not be calibrated.
• Inspect the exhaust system for leaks. Inspect the
gaskets and the exhaust bellows joint. If a leak is
found, make repairs.
96
Maintenance Section
Water Pump - Inspect
SEBU7150-05
i02624237
Water Pump - Inspect
SMCS Code: 1361-040
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump
- Disassemble and Water Pump - Assemble” for
the disassembly and assembly procedure. If it is
necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual,
“Water Pump - Remove and Water Pump - Install”.
Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Parts Manual
for the correct part numbers for your engine or
consult your Caterpillar dealer if repair is needed or
replacement is needed.
i01906792
Water Temperature Regulator Replace
SMCS Code: 1355-510
Replace the temperature regulators before the
temperature regulators fail. This is a recommended
preventive maintenance practice. Replacing the
temperature regulators reduces the chances for
unscheduled downtime.
NOTICE
Failure to replace the temperature regulators on a
regularly scheduled basis could cause severe engine
damage.
Never operate the engine without the temperature regulators installed.
If the temperature regulator is installed incorrectly, the
engine may overheat, causing cylinder head damage.
Ensure that the new temperature regulator is installed
in the original position.
A temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or a seizure of the pistons.
A temperature regulator that fails in a partially opened
position can cause overheating or overcooling of the
engine.
A temperature regulator that fails in the open position
will cause the engine operating temperature to be
too low during partial load operation. Low engine
operating temperatures during partial loads could
cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
For the procedure to replace the temperature
regulators, see the service information that is
provided by the OEM of the temperature regulators.